PROCESS FOR THE PRODUCTION OF SPONGE CLOTH

Abstract: Process for the production of sponge cloth (10) dyed a background colour at the dye works using reactive and other dyes, and at the printing works for decorative printing by a transfer process on one side (16) on which side the curled threads (13) are of polyester.

Description: Process for the production of sponge cloth The invention concerns processes for weaving, especially for weaving sponge cloth. To make fabrics, natural fibres such as cotton, linen, jute, hemp and others can be used, or else artificial fi¬ bres such as polyesters and others. Sponge cloth is a particular type of woven fabric on which there are rings or curls of yarn on one side or on both. This cloth is composed of a single series of weft threads and two of warp threads, woven on different beams since different tensions are needed for each. The first, with the basic threads, is woven at normal ten¬ sion, the second with curled threads, at a looser tension. Other characteristics concern the different methods of dyeing; this consists of applying substances to the fibres that alter the relations between incident light and reflec¬ ted light absorbed and spread by the fabric to create the optical sensation of colour. There are many ways of applying dye to fibres; these include the use of direct, basic, acid, naphtholic, vat, sulphur and reactive dyes, namely those that dissolve by reaction with groups of molecules present in the fibre to produce non-reversable covalent links. Dyeing can be carried out at different stages during the weaving process and may in fact be done on the fibre, on the woven fabric or on the finished garment. By using the printing process dyeing can be localised to produce areas of different colours and so form a pattern. Various methods may be followed. One of these is transfer print ing . For this dyes transferable by sublimation are used, ap¬ plied in patterns onto paper which is then placed in con¬ tact with the fabric. Subjected to heat and pressure the dye sublimes and fixes on the fibre in a soluble form that becomes solid. This method gives results of very good quality but is also expensive and, further, can only be used on thermoplastic synthetic fibres, particularly polyesters. Another method is rotograveur using engraved rollers. But with this type of printing only a limited number of colours can be used as a roller is needed for each colour; it is also suitable only for long runs and this places a limit on the variety of patterns. Another method is silk screening on boards. One board is required for each colour. Attractive results are ob¬ tained but the method is expensive. From the foregoing it is clear that in the case of sponge cloth, requiring a variety of patterns and therefore only short runs for each one, the most suitable method is trans¬ fer printing. But as sponge cloth is usually made of natural fibres this method cannot be recommended since, with transfer print¬ ing on natural fibres, the colour does not become fixed and is therefore lost in the wash. This means that other methods must be used involving the disadvantages already mentioned. The above invention eliminates or reduces these disad¬ vantages and offers other important advantages as will be explained below. Subject of the invention is a process for producing sponge cloth for which weft,' basic and curled threads are used on one or on both sides and employing natural and artifi¬ cial fibres . According to the invention on one side of the fabric are curled threads of artificial fibres. The curled threads on that side can be all, or at least mostly, of artificial fibres. That same side may have areas of curled threads of arti¬ ficial fibres and others of curled threads of natural fibres, these areas being so situated as to form the de- sired pattern. On the other side of the fabric the weft, basic and curled threads are of natural fibres. Cutting is done, or is not done, on the sponge cloth as the case may be . Dyeing proceeds in two stages: the first takes place in the dye works where the natural fibres are treated using direct, basic, acid, naphtholic, vat, sulphur and reac¬ tive dyes; the second stage is done at the printing works where transfer printing uses dyes transferable by subli- mation applied to patterns on paper and transferred to the side of the fabric on which are the curled threads of artificial fibres. The process offers evident advantages. All parts of the cloth made of .natural fibres can be dyed at the dye works using reactive or another type of background dye, ensuring high quality combined with low cost. The decorated side, woven in curled polyester threads, is dyed at the printing works by transfer printing which is inexpensive and makes possible a wide variety of pat¬ terns and colours. By these means sponge cloth is produced with reactive or another type of background colour while benefiting from all the decorative effects obtainable with dyes trans¬ ferable by sublimation applied to paper. All the above advantages can be secured by inexpensive means, combining high output with a wide variety. Characteristics and purposes of the invention will be made still clearer by the attached figures. Fig.1. A piece of sponge cloth with complete curled threads on the patterned side. Fig.2. Diagram to show the weave. Fig.3 A piece of sponge cloth with cutting on the pat ¬ terned side. Fig. . Diagram of the weave of the piece in Fig. 3. Fig.5 Diagram of the weave of a piece of sponge cloth where cutting has been done on the side with curled threads of a polyester fibre. Fig.6. Diagram of the weave of a piece of sponge cloth where cutting has been done on the side with curled threads of natural fibres. In the length of sponge cloth 10 the weft threads 11, the basic threads 12 and the curled threads 14, on the wrong side of the material, are of natural fibres. The curled threads 13 on the right side of the material are of polyester fibre. The background colour of the material has been dyed at the dye works while a printing process has been used for the patterns 15 on the side with ' curled polyester threads 13. These patterns give a highly ornamental effect as the printing process with transfer from prepared paper makes possible achievement of maximum quality, perfection and variety . The piece of sponge cloth 20 is made by the same method as the above piece 10, and . then given the cutting process. The weft threads 21, basic threads 22 and curled thresds 24 on the wrong side, of natural fibres, can be seen. The curled threads 23 on the right side are of polyester. As will be seen from the illustration the curled threads have been "shaved". The side with curled polyester threads 23 presents deco¬ rative motifs 25 of great design variety and quality. In the piece of material 30 with weft threads 31, basic threads 32 and curled threads 34 of natural fibres on one side and with curled polyester threads 33 on the other side, cutting has been done on the curled polyester threads 33. In the piece of material 40 with weft threads 41, basic threads 42 and curled threads 44 of natural fibres on one side and with curled polyester threads 43 on the other side, cutting has been done on the curled threads 44 of natural fibres .

Claims: C l a ims 1. Process for the production of sponge cloth ( 10,20, 30,40) which is then dyed, comprising weft threads ( 11, 21, 31,41), basic threads ( 12,22,32,42) and curled threds ( 13, 14) (23,24), ( 33 , 34 ) , (43 , 44 ) on one or on both sides ( 16, 17) (26,27), (36,37), (46,47) made of natural and artificial fibres, characterized in that the curled threads ( 13,23,33,43) on one side ( 16,26,36,46) are of artificial fibres. 2. Process as in claim 1, characterized in that the curled threads ( 13,23,33, 3) on the one side ( 16,26,36,46) are made entirely of arti¬ ficial fibres. 3. Process as in claim 1, characterized in that the curled threads ( 13,23, 3 * 3 ,43) on the one side ( 16,26,36, 6) are made for the greater part of artificial fibres. 4. Process as in claim 1, characterized in that the curled threads ( 13,23,33,43) on the one side ( 16,26,36,46) are made of artificial fibres in some areas of said side ( 16,26,36,46). 5. Process as in claim 1, characterized in that the artificial fibres are of po¬ lyester. 6. Process as in claim 1, characterized in that the fibres of the weft threads ( 11,21,31,41) and of the basic threads ( 12,22,32,42) are natural . 7. Process as in claim 1, characterized in that the fibres of. the weft threads ( 11,21,31,41), of the basic threads ( 12,22,32,42) and of the curled threads ( 14,24,34,44) on the other side ( 1 7 , 27 , 37 , 4 7 ) a r e na t u r a l . 8. Process as in claim 1, characterized in that dyeing is done on the side ( 16, 26,36,46) on which curled threads ( 13,23,33,43) or areas of curled threads ( 13,23,33, 3) made from artificial fibres, are present, dyeing method being that of trans¬ fer of dyes by sublimation applied to designs on paper. 9. Process as in claim 1, charac erized in that dyeing is carried out in two sta- ges, the first for colouring the natural fibres ( 14,24,34, 44) at the dye works using direct, basic, acid, naphtholic, vat, sulphur, reactive or other dyes, and the second stage being done at the printing works for printing by transfer of dyes by sublimation applied to designs on paper, onto the side ( 16,26,36,46) of the material containing ,the curled threads ( 13,23,33,43) made of artificial fibres. 10. Process as in claim 1, characterized in that the sponge cloth (20) is given the cutting process on both sides (26,27). 11. Process as in claim 1, characterized in that the sponge cloth (30) is given the cutting process on one side only (36) with curled threads (33) of polyester . 12. Process as in claim 1, characterized in that the sponge cloth (40) is given the cutting process on one side only (47) with curled threads (44) of natural fibres.

Inventors: BIANCHI MARCO, PICCOLI BRUNA, BIANCHI, MARCO, PICCOLI, BRUNA
Applicants: BIANCHI MARCO, MARCOTEX SRL, PICCOLI BRUNA, BIANCHI, MARCO, MARCOTEX S.R.L., PICCOLI, BRUNA
Application year: 1994
Main classification: D03D27
IPC codes: D03D27